cablecalc

CASTLINE SYSTEMS

CABLECALC version 3

FOR WINDOWS

Copyright © 1999 Castline Systems All rights reservedMicrosoft is a registered trademark of Microsoft Corporation.Windows is a registered trademark of Microsoft Corporation.All other registered trademarks are acknowledged.ReferencesRequirements for Electrical Installations IEE Wiring Regulations Sixteenth Edition BS7671 : 1992 Incorporating Amendment No. 1, 1994 (AMD8536).IEE Inspection & Testing Guidance Notes 3Protection Against Electric Shock IEE 16th Edition Wiring Regulations Guidance Notes Number 5 in a seriesCastline Systems reserve the right to change specifications without notice.

Castline Systems,Welford House, 39 Alfriston Road,

Worthing, West Sussex, BN14 7QS,United Kingdom.

Telephone 01903 201837

CASTLINE SYSTEMS CableCalc •••• 5

Contents

Overview 7

About This Reference ............................................................................... 7Use of Cablecalc for Windows...................................................... 7

About Cablecalc for Windows.................................................................. 7

Getting Started 9

Installation................................................................................................ 9Starting Cablecalc..................................................................................... 9

Windows 95 or 98......................................................................... 9Before you begin .................................................................................... 10

Help............................................................................................ 10Starting Cablecalc................................................................................... 10

Starting Cablecalc ....................................................................... 10Starting a Calculation.................................................................. 10Saving Your Work (levels 2-3-4) ................................................ 11Setting Your Printer .................................................................... 11Printing Reports.......................................................................... 11

Correcting Calculation Errors ................................................................. 12Hint Button................................................................................. 12

Viewing the sample file .......................................................................... 12Setting up a Project File.......................................................................... 13Project Default Values............................................................................ 13Create Distribution Boards ..................................................................... 14

Create Distribution board ............................................................ 14Formulae and Conversion....................................................................... 15

The Cable Calculator 17

Tab 1 - Supply........................................................................................ 17To calculate and save a cable ...................................................... 17Type of Circuit:........................................................................... 17Diversity ..................................................................................... 19

Tab 2 - Cables ........................................................................................ 20Tab 3 - Protection ................................................................................... 21

Overload / short circuit protection ............................................... 21Type of circuit............................................................................. 21Select Protective Device.............................................................. 21

Tab 4 – Derating..................................................................................... 23Thermal insulation (Ci) ............................................................... 23

Tab 5 - CPC Details................................................................................ 25Select CPC.................................................................................. 25

CASTLINE SYSTEMS CableCalc •••• 6

Tab 6 - Calculate .....................................................................................27Cable Size....................................................................................27Volt Drop ....................................................................................27Impedance ...................................................................................28

Calculation related problems ...................................................................281.) Cable Size...............................................................................282.) Volt Drop ...............................................................................293.) Impedance ..............................................................................29

The Project Manager 31

The Project Manager ...............................................................................31Buttons ........................................................................................32Menus..........................................................................................33

Projects: A beginners guide. ....................................................................341) Create Project file ....................................................................352) Create Distribution board within the project file.......................353) Save a circuit within the Distribution board file. ......................36

To calculate and save a cable...................................................................37To calculate a cable......................................................................37To calculate a sub main cable.......................................................37

Utilities 39

The Time Curve Utility. ..........................................................................39The menus ...................................................................................39

The Conduit Utility..................................................................................42The menus ...................................................................................42

The Trunking Utility................................................................................44The menus ...................................................................................44

The Diversity Utility................................................................................45The menus ...................................................................................46

Trouble Shooting 49

Version....................................................................................................49Where to look for answers .......................................................................49Computer Related Problems ....................................................................49Operation problems .................................................................................51

Error codes ..................................................................................51

Glossary of Terms 53

CASTLINE SYSTEMS Cablecalc Overview •••• 7

Overview

About This ReferenceThis reference is a guide to the use of the Cablecalc for Windows programme, and covers thegeneral aspects of operating the various features available. It does not profess to be a WindowsTutorial. However, some points essential to the operation of the programme will be covered.

Use of Cablecalc for WindowsCablecalc for Windows is for use by electrical contractors, electrical engineers and consultantsthat possess a good general knowledge of the electrical design and installation trade. Many ofthe terms and descriptions used in Cablecalc for Windows will be very obvious to them, butwill be meaningless to any non electrical users of the programme. We must stress thatCablecalc for Windows is not a magic wand for creating electrical design engineers andemphasise that the experience and judgement of the competent electrical engineer conversantwith the IEE Wiring Regulations will greatly enhance the use of this programme.

About Cablecalc for WindowsCablecalc for Windows is designed to produce cable sizing and circuit evaluation data tocomply with the IEE Wiring Regulations, Requirements for Electrical Installations (BS 7671 :1992) incorporating amendment No. 1, 1994 (AMD 8536). Reports may be printed on anyprinter supported by Microsoft Windows, and may also be stored on disc and recalled later forupdating (as well as ease of generating file copies for office use).

NOTE: Cablecalc for Windows version 3 levels 2 – 3 & 4 will export circuit data to FormFill for Windows versions 2 and 3.

All software supplied by Castline Systems has been fully checked for all known viruses beforedispatch. Please note that all Castline Systems software has the name of the licensed userembedded into the code. Should the software detect that it has been installed incorrectly (orthat no company name has been entered) then it will operate in Unregistered Demonstrationmode only.

Cablecalc ‘Plus’ for Windows (level 2) provides an invaluable set of additional utilitiesoffering the following additional features:-

• Time Curve

• Conduit

• Trunking

• Diversity

• Distribution board schedules

CASTLINE SYSTEMS Cablecalc Overview •••• 8

• Formulae and conversions

• Lighting circuit calculations

• Busbar trunking calculations

Cablecalc ‘Elite’ for Windows (level 3) provides the following additional features:-

• Phase balance graphs

• Schematic diagrams

• Circuit charts

• Multiple circuit calculations

Cablecalc ‘Professional’ for Windows (level 4) provides the following additional features:-

• Single Line Diagrams

• Schematic diagrams

• Cost details

CASTLINE SYSTEMS Cablecalc Getting Started •••• 9

Getting Started

InstallationTo install Cablecalc for Windows Version 3, place the CD in your CD-ROM drive and clickstart, then run, then type D:\setup and click ok. Cablecalc will be installed to C:\programfiles\Cablecalc.

It is recommend that your computer is set for a resolution of 1024 x 768 or greater andrecommend a minimum requirement of 640 x 480.

Starting Cablecalc

Windows 95 or 98To run the programme from Windows 95 or Windows 98:

To run the programme from the ‘Start’ Button

• Click the ‘Start’ button

• Select ‘programs’

• Select ‘Castline’.

• Select ‘Cablecalc’.

To run the programme from the Castline Program Group

• Double click on the Cablecalc for Windows icon in the Castline Program Group

It is recommended that the screen resolution be set to 1024 x768. However the programme willwork in 640 x 480 but some of the features may appear distorted or may not be accessible on thescreen.The resolution may be changed from the ‘Windows Control Panel’

• Click the ‘Start’ button

• Select ‘Settings’

• Select ‘Control Panel’

• Select ‘Display’


Before you begin

HelpIf you require additional help whilst using Cablecalc for Windows, just press the F1 key at anytime to bring up either a help screen related to the area of the programme that you are using, orthe main Cablecalc for Windows help index. To return to the list below after reading each of theitems, just click on the Back button below the menus. Finally, to exit Help and go back to theprogramme itself, press Alt & F4 or click on the File menu then choose Exit.

Starting Cablecalc

Starting CablecalcWhen you load Cablecalc for Windows, a title screen will be displayed while the mainprogramme is loading. The title screen will then clear to display the ‘Cable Calculator’ screen

Please note that there is a quick help system built in to the main screen. As the mouse cursorpasses over the various controls on the main screen a brief description of their uses is displayed

Starting a Calculation.In the centre of the screen are the boxes, which allow you to enter the data needed to performcalculations. The default values are already filled in but can be changed, either by over-writingthem or by changing the user default settings from the ‘Set Defaults’ menu.

You will notice that on the lower edge of the Cable Calculator there are Index Tabs. Each ofthese tabs relates to a section of the current form and most of them will require the input of data.To access the input screen associated with each Tab, click on the tab itself.


Boxes on the forms mainly require either text or a numeric value to be entered into them. If a boxhas a button with an arrow pointing downward in it attached to it then pressing this button willdrop down a list of possible options that can be chosen. To select one of these options just clickonce on it using the mouse.

NOTE: If there are more options in the list that can be displayed at any one time on the screen, a scroll bar will be shown at theright-hand side of the list.

Small blank square boxes may be selected by clicking on them once with the mouse, and areusually either/or or yes/no choices (e.g. the ‘Separate cable’ facility in the CPC details section).When you click on this type of box the box will either becomes checked or will become blank.

Small round boxes surrounded by a frame denote various options, only one of which can beselected at any time (e.g. the Type of Circuit buttons on the Voltage screen).

NOTE: In all cases context-sensitive help about any part of the data entry screens (and the rest of the programme) is available bypressing the F1 key.

Saving Your Work (levels 2-3-4)Once you have completed your calculations, the next operation is to print them. However, it isadvisable to save them first. This is achieved by choosing Open/Save File from the File Menuwith the mouse or by pressing Alt & F together, followed by O. See ‘Project Manager’

NOTE: You can also re-load this calculation should you need to come back to it at a later date by choosing the OpenCalculation File option from the File menu (Keyboard Shortcut: Press Alt & F followed by O).

Setting Your PrinterBefore printing you may wish to check that the settings for your particular printer are correct.Choosing Printer Set-up from the ‘File’ menu will display the standard Windows Printer ControlBox and allow you to change any required settings. However, in most cases this should not benecessary. Refer to Printing Reports below as well as the Troubleshooting Guide later in thismanual. Please note that the Printout Defaults button allows you to customise the printout to yourexact requirements and can add/modify such items as Job Reference, Cable Reference etc. andallow the setting of a top margin so that headed paper can be used.

Printing ReportsTo print your Report, choose Print from the file menu or press the Print button at the bottom ofthe Calculate screen. The current result will then be printed to the local printer. (KeyboardShortcut: Press Alt & F followed by P (For more details on printers and their configuration, referto the Microsoft Windows User Guide supplied with your computer). See also theTroubleshooting Guide below. Please note the Printer Set-up may be accessed from any of thefollowing methods: -

a) From the file menu for configuring the printer & paper in use,b) Keyboard Shortcut: Press Alt & F followed by R


c) Or the button on the Calculate Screen (used for setting various messages as well as thestyle of type font for the printout).

Print Preview will allow you to see what your printout will look like before actually printing it(see note below). It is available both by pressing the Print Preview button on the Calculatescreen as well as choosing Print Preview from the file menu (Keyboard Shortcut: Press Alt & Ffollowed by V). To exit from Print Preview press Alt & F4.

NOTE: Cablecalc for Windows will support colour printers if available and will print using the same colour(s) as displayed onthe screen. Also, what you see on the screen in the Print Preview is a representation of what appears on the printer, shown to thecorrect scale. The printouts will, in nearly all cases, look clearer than this.

Correcting Calculation ErrorsIf you have an error in a calculation (i.e. a Fail) when you press the Calculate button you will seethat on the right hand side of the calculation box there are three coloured indicators which showeither “PASS” or “FAIL” dependant on the result of the calculation(s). Look at the valuesassociated with whichever indicator(s) that show “FAIL” and one or more of them should behighlighted in RED. This will give you an idea of the cause of the problems with the calculation.Figures 3a & 3b show some examples of this.

Hint ButtonIf a “FAIL” situation is flagged then the hint button will appear. Clicking on the hint button willreveal some possible explanations and solutions for the calculation failure. To return to thecalculation screen click the hint button once more.

Viewing the sample fileWe have included a small sample file called Castline. To view this file from the Cable calculatorscreen click the command button ‘View Distribution Boards’ located at the bottom of the CableCalculator window. This will select the Project Manager, which will display distribution boardand circuit details.

To view the different types of schedules and reports that have been included in the sample file,click on the command button ‘Schedules’. In the schedule screen you may select six types ofschedules and graphs from the menu schedule at the top of the screen. You may move betweendifferent distribution boards by selecting from the bottom of the screen. Click ‘close’ to return tothe programme manager.


Setting up a Project FileTo create a new project file for use with Cablecalc, select Set Up Project from the File menulocated on the top menu bar, giving your project a unique name using no more than eightcharacters. (Note that when entering the name certain reserved characters, e.g.! ” £ $ % ^ & * ( )_ /\ | < > # ~ @ ; : ? [ ] { } . , ‘ ¬ = cannot be used). You can also set up a new project file fromthe New Project button on the Project Manager screen. For more information on setting upproject files see Projects: a beginners guide.

Project Default Values

Select ‘Set Defaults’ from the top menu bar

Or

From the Project Manager select ‘Details’ from the top menu bar

This area covers the supply characteristics for the project in question and will be the basis for allof the calculations performed in this project.

The items covered are: -

Supply Voltage

Single phase e.g. 240

Three phase e.g. 415

Open Circuit e.g. 240

Volt Drop

Max permissible e.g. 4%

Supply impedance (Ze)

Ze (SPN) e.g. .25

Ze (TPN) e.g. .15

Ambient Temperature

Air e.g. 30

Ground e.g. 15

Soil Resistivity e.g. 1.2


Short Circuit Current

Pscc (kA) e.g. 16

Power Factor

P.F. e.g. 1

Supply Details

Supply reference e.g. DB-1

Supply location e.g. Basement

Supply description e.g. Switch room at J.Bloggs & Co.

Supplied from

Supplied from e.g. Source

Supplied from circuit e.g. Main incomer

If you want to revert to the original default values click on Use Default Values.

Create Distribution Boards

Create Distribution boardThe Cablecalc ‘Project Manager’ must be displayed on the screen before this can be achieved.

To display the Cablecalc Project Manager if it is not already displayed, click ‘View DistributionBoards’ at the bottom of the Cable Calculator screen (Supply Tab)

OrFrom the drop down menus on the top bar select ‘File’ then ‘Open/Save File’

First select a Project by clicking on a project displayed in the project list

Select ‘Distribution Boards’ from the top menu bar and then select ‘New Distribution Board’to display the new distribution board entry dialogue.

Enter the name of the distribution board using less than 20 characters. (Spaces are permitted).


Click OK to create the distribution board database file. The new distribution board should nowappear in the Distribution Board list.

Any number of Distribution boards may be added to a project file.

NOTE: Distribution boards cannot be re-named once they have been created therefore if you do wish to change the name of adistribution board copy it naming it with the new name and then delete the original.

Formulae and ConversionThis section provides a handy ready reckoner set of information for converting between units aswell as providing a simple electrician’s calculator.

CASTLINE SYSTEMS Cablecalc The Cable Calculator •••• 17

The Cable Calculator

Tab 1 - Supply

This area covers the supply characteristics for the circuit in question and most of the inputs canbe pre-set using the User defaults set up facility from the ’Set Defaults’ menu (Voltage, Ze,PSCC, Pf and Volt drop). The main user inputs are for the selection of the type of circuit; theLoad input (Amperes) and the Length of the circuit (metres).

To calculate and save a cableTo calculate a cable, first select the appropriate distribution board from the list in the ‘projectmanager’. This will then load the supply characteristics for that distribution board in to the cablecalculator, in the cable calculator window. Fill in the circuit number, phase and descriptionboxes and then proceed with your calculation as normal then click ‘save’ on completion.Confirm details in the ‘save circuit’ screen and click ok.

Type of Circuit:

Radial circuit

This is the default option and is for a category 1 circuits

Radial circuits are conventional circuits feeding socket outlets,lights etc.


Ring circuit

Ring final circuits are circuits arranged in the form of a ring andconnected to a single point of supply.

This option is requires input for the distance (metres). The Loadinput box will be disabled, as the load for the calculation of voltagedrop for the circuit is taken as 25% of the protective device rating.

NOTE: The Distance input for a ring circuit is to the half way point of the circuit or the distance to the furthest socket outlet, notthe total length of the cable from the protective device and then back again.

NOTE: Ring circuit. The Load input box will be disabled, as the load for the calculation of voltage drop for the circuit is takenas 25% of the protective device rating.

Sub main

Circuits feeding distribution boards.

To calculate a sub main cable: From the ‘project manager’,select the distribution board that the cable is coming from, then onthe cable calculator screen select ‘sub main’ and then select threephase if relevant. A yellow grid should now be visible. In the leftcolumn of the grid add the load in amperes, in the middle columnthe distance in metres, then when you click to the right column adrop down list will appear, select the relevant distribution boardthat the cable is feeding. If your sub main cable is looping to morethan one distribution board then complete section two asappropriate. Click ok and then go back to the cable calculatorscreen and continue as normal. Another yellow grid will appeardisplaying the result of the sub main(s), click ok to continue, andthen click on ‘save’.

Lighting circuit

This option is for category 1 circuits that are looped together e.g.street lighting installations, three plate lighting installations and submains. Each section of the circuit requires the load at that point andthe distance for that section of the circuit. Totals for the entirecircuit are displayed at the bottom of the input form and calculatedas the cursor moves to the next position.

Star Delta circuit

This option is for a category 1 star delta circuits and requires thedistance from the starter to the motor and the full load current forthe motor. The root three load is displayed in a separate text boxand is the load that will be carried by each of the six conductors inthe cable(s).


Motor

Circuits feeding motors.

DiversityDiversity may be applied to the circuits, anything between 5% and 100% in steps of 5%, with100% representing the full load. For more information regarding Diversity see the I.E.E. On SiteGuide appendix 1 Maximum Demand and Diversity.

NOTE: the input is not accepted until the cursor is moved down and is clear of the last input.


Tab 2 - Cables

This area covers the cables available and their are no user defaults available. Cable parametersshould be selected in the following order

Conductor

Type

Insulation

Cable Type

Installation method

Cores

Size/Calculate

Parallel cables

Selecting Calculate will calculate the minimum size of cable suitable for the circuit, selecting anactual cable size from the drop down list will evaluate the circuit based on the size of cableselected.


Tab 3 - Protection

Overload / short circuit protectionSelect either overload and short circuit protection or Short circuit protection only.

See regs 473-01 and appendix 4 sections 4 & 5 for details

Type of circuitSelect the type of circuit from the options in this section (Fixed equipment / Socket outlets), themaximum permissible disconnection time will be displayed for the option selected.

Maximum disconnection time permitted.

Fixed equipment 5.0 secs.

Socket Outlets 0.4 secs.

Socket outlets special locations 0.2 secs.

See On Site Guide Section 3.5 - Disconnection Times.

Select Protective DeviceThis area covers the Protective devices available; there are no user defaults available. Parametersmay be selected in any order. The system default protective device type is the BS 88 Cartridgefuse, this was chosen as the system default because it contains the greatest range of currentratings (2-800 A). Cablecalc for Windows will automatically select the lowest protective devicesize greater or equal to the load for the circuit. To increase or decrease the protective devicerating click on the arrows below the Rating (Amperes) display window (left arrow to decrease,right arrow to increase). If the protective device rating selected is lower than the load for thecircuit then the colour of the display will change from black to red.


The Max Zs (ohms) window displayed is the impedance value for the protective device selected.

NOTE: The total impedance for the circuit (including the external impedance) must notexceed this value or else a fail situation will arise.

The Multiplier display shows the figure that is multiplied to the protective device rating toprovide the tripping current, and is used in the following formulae to obtain the protective deviceimpedance (Zs): -

Open circuit volts / Protective device rating x multiplier

Multipliers for miniature circuit breakers used in Cablecalc for Windows are as follows: -

Type 1 4

Type 2 7

Type 3 10

Type 4 50

Type B 5

Type C 10

Type D 50

Example: type 2 mcb - 10ampere - 240V open circuit voltage

240 / 10 x 7 = 3.428 ohms

Magnetic Setting window (ACBs and MCCBs only) use the control below this window to adjustthe setting of the circuit breaker (left arrow to decrease, right arrow to increase).


Tab 4 – Derating

This area covers the derating factors that will affect some of the characteristics for the cableselected, these include: -

the effective current rating,

the operating temperature,

the millivolt drop per metre.

Temperature (Ca)

From the drop down list select the ambient air temperature applicable for the circuit, thecorrection factor for the selected temperature is displayed in the adjacent text box. User pre-setavailable

NOTE: The Temperature for direct buried cables and cables in ducts is based on a ground temperature of 15°C, the temperaturefor all other cables is based on an ambient temperature of 30°C.

Grouping (Cg)

From the drop down list, select the number of circuits or multicore cables grouped with thiscircuit, the correction factor for the selected number of cables is displayed in the adjacent textbox.

NOTE: If due to known operating conditions, a cable is expected to carry not more than 30% of its grouped current rating, itmay be ignored for the purpose of obtaining the rating for the rest of the group. See regs appendix 4 tables 4B1, 4B2 & 4B3 fordetails.

Thermal insulation (Ci)From the drop down list, select the length of thermal insulation as appropriate, the correctionfactor for the selected length of thermal insulation selected is displayed in the adjacent text box.


NOTE: See regulation 523-04 & table 52A for details.

Fuse (Cf)

The correction factor for the protective device selected will be displayed. If a rewireable fuse toBS 3036 has been selected then a factor of 0.725 will be displayed; all other protective deviceswill display a factor of 1.

Correction Factor (Ct)

The total correction factor for the circuit will appear in this text box; this factor will be applied tothe tabulated current rating for the cable.

Calculation method

The Use worst case only option will apply the lowest of all the correction factors.

NOTE: This is not the recommended method of calculating the correction factor and should be used with caution.

The Calculate using all factors option (standard method) will apply the sum of all the correctionfactors to the tabulated current rating for the cable.

NOTE: See appendix 4 for details.


Tab 5 - CPC DetailsThis area covers the circuit protective device (cpc) options and contains three tabulatedsections

Select CPCVarious options are available for the selection of the cpc for the cable (you may select more thanone option) and include: -

Sheath or Armour

Internal core

Conduit

This section displays a list containing light duty and heavy-dutyconduit sizes from 16mm up to 32mm. If Steel conduit is selectedthen the conduit resistance may be included in the earthcalculation.

Trunking

This section displays a list containing trunking sizes from 50mm x50mm up to 300mm x 150mm If Steel trunking is selected then theresistance of the trunking may be included in the earth calculation.

Separate cable

This option if selected displays four methods for adding a separatecpc: -

The default is to calculate the size in accordance with Table 54G

Use same size as cable

This will add a separate cpc to the calculation that is the same sizeas the cable under evaluation.


Calculate size

This will calculate the size of a separate cpc up to a maximum sizeof 1000mm²

Select size

This option will display a drop down list box containing cpc sizesfrom 1.0mm² to 1000mm² select the desired size from the list.


Tab 6 - Calculate

This area displays a summary of the calculation/evaluation and is divided into three logicalsections providing a pass/fail flag for each section. For more information see Calculation RelatedProblems and Correcting Calculation Errors elsewhere in this manual. At the bottom of thissection are buttons to Save, Printout Defaults, Print Preview and Print, these items aredescribed elsewhere in this manual.

Cable Size

This section displays the cable size, the number of cables inparallel, the length of the circuit, a description of the cable, thevoltage and phase details and the tabulated and effective ratings ofthe cable. To increase/decrease the cable size or add/subtract cablesin parallel, click on the arrows below the relevant items.

Volt Drop

The calculated volt drop and the permitted volt drop for the circuitis displayed both in volts and as a percentage of the line voltage.The millivolts per Ampere per metre (mV/A/mtr), and thecorrected mV/A/mtr are also displayed. The Tabulated values of(mV/A/mtr) are the values taken from the tables in the IEEregulations, or alternatively from cable manufacturers data sheets.The corrected values are the tabulated mV/A/mtr values withcorrection for operating temperature applied. The volt dropcalculation is based on the corrected value.


Impedance

This section displays the following information: -

R1

R2

R1+R2

Zs

PSCC

Withstand time

cpc size

Zsc (origin)

Zsc (circuit)

Earth Fault Current

Calculation related problemsCalculation problems are highlighted within the calculate screen by FAIL flags and the relevantitem(s) displayed with a red background. These will be in the following areas:

1.) Cable SizeA fail situation here could be caused by: -

Problem Effective current rating highlighted. The load exceeds the effective currentrating of the cable

Suggestion Increase the cable size.Suggestion Add an additional cable in parallel.Suggestion Check that the derating factors are correct especially the factor for grouping as

in some circumstances this may be ignored (see regulations appendix 4 notes totable 4B2).

Problem Load highlighted. The effective current rating of the cable is less than the ratingof the protective device.

Suggestion Increase the protective device size (the protective device rating is displayed red ifthe value is too low).


2.) Volt DropA fail situation here could be caused by: -

Problem Volt Drop highlighted The calculated volt drop exceeds the maximumpermitted volt drop.

Suggestion Increase the cable sizeSuggestion Add an additional cable in parallel.

3.) ImpedanceA fail situation here could be caused by: -

Problem Zs highlighted. The cable/cpc Zs value is greater than the protectivedevice Zs value

Suggestion Increase the cable sizeSuggestion decrease the protective device sizeSuggestion Increase the cpc sizeSuggestion Add a separate cpcSuggestion Check that the supply impedance(Ze) is correct, (the impedance of the cable/cpc is

added to the Ze, this total must be less than the Zs value of the protective device).

Problem R2 highlighted. There is no cpc present.Suggestion Add a cpc

The Hint button will offer some suggestions for ‘Fail’ situations.

CASTLINE SYSTEMS Cablecalc The Project Manager •••• 31

The Project Manager

The Project Manager

The Project manager is the heart of the Cablecalc programme. It is from the Project manager thatprojects can be created and distribution boards added and circuits edited or recalculated.

Projects may be selected using the Project dialogue box together with the Drive and Directorylists located at the top of the ‘Project Manager’.

Circuit sort order may be displayed in three different ways by selecting either ‘Numeric’ ‘Phase’or ‘None’ from the ‘Sort order’ section.

The circuit grid details may be changed using the ‘Overview’ ‘Device Details’ ‘Cable Details’‘Cost Analysis’ buttons (Level 4 only).

The ‘Summary’ section provides totals for either the design Amperes or the Diversified Amperes(The circuit design loads multiplied by the diversity factors).

The Voltage Impedance and Fault current for the board is displayed at the bottom left of the‘Project Manager’.


Buttons

Edit Circuit

Select a circuit from the grid by clicking on any grid cell andthen click the ‘Edit Circuit’ button to reload the calculation.

New Circuit

Click the ‘New Circuit’ button to reload the ‘CableCalculator’.

Delete Circuit

Select a circuit from the grid by clicking on any grid cell andthen click the ‘Delete Circuit’ button to delete a circuit.

Copy Circuit

Select a circuit from the grid by clicking on any grid cell andthen click the ‘Copy Circuit’ button to copy the circuit.

Schedules

This will load the ‘Report’ section of Cablecalc

Calculate ***

Click this button to recalculate all of the circuits in thedistribution board.

Calculate All

Click this button to recalculate all of the circuits in the all ofthe distribution boards in the project.

Exit Manager

Return to the ‘Cable Calculator’.

Overview

Click this button display the default calculation results for thecurrently loaded distribution board.

Cost Analysis

Click this button display the costs currently loadeddistribution board. (Level 4 only).


Device Details

Click this button display the protective device details for thecurrently loaded distribution board.

Cable Details

Click this button display the cable details for the currently loadeddistribution board.

Menus

Close

This will return to the ‘Cable Calculator’

Project

New Project Create a new project

Copy Project Create a new project

Delete Project Create a new project

Distribution Boards

New Distribution Board Add a new Distribution board

Copy Distribution Board Copy an existing Distributionboard

Delete Distribution Board Delete an existing Distributionboard

CAD

Display the Drawing Utility (Level 4 only).

Calculate

Calculate This

Distribution Board Select this menu to recalculateall of the circuits in thedistribution board.

Calculate All Select this menu to recalculateall of the circuits in the entireproject.


Details

Click this button display the cable details for the currentlyloaded distribution board.

Export

Click this button display the cable details for the currentlyloaded distribution board.

Projects: A beginners guide.

Project File

Distribution Board Distribution Board Distribution Board

e.g. FACTORY1

e.g. DB1 - Lighting e.g. DB2 - Power e.g. DB3 - Heating

Circuits Circuits Circuits

As you can see from the above diagram, a project file contains all the elements of the job. Pleasenote that calculations can not be saved until a suitable distribution board file has been set up andloaded.

A project file is the container file for any number of distribution board files

A project file name must not consist of any reserved characters or use any spaces (see Setting upa Project).

A Distribution Board file is the container file for saving calculation results (circuits).

A Distribution Board file name may be more than eight characters in length and may containspaces.

A circuit file may only be saved to a Distribution Board file.

A circuit file must contain a circuit reference number e.g. 5 and a valid phase reference coloure.g. RYB (you will be prompted for this information when click on the “Save Circuit” button inthe “Project Manager” form). Valid phase references are: - R Y B and RYB.


1) Create Project file

A project file may be created either from the Cablecalc Project manager or from the New ProjectDialog box.

a) To create a Project file from the New Project Dialogue box, from the File Menu select SetUp Project.

b) To create a Project File from the Cablecalc Project manager, from the File menu selectOpen/Save File to display the Cablecalc Project manager. Click on the New Projectbutton to display the New Project Dialog box.

In the text box marked File Name enter the name of the new project (using no more than 8characters) e.g. Factory1 and then click OK.

2) Create Distribution board within the project file.

The Cablecalc Project manager must be displayed on the screen before this can be achieved. Todisplay the Cablecalc project manager from the File menu select Open/Save File.

First select a Project by clicking on a project displayed in the project list.Click on the button marked New Dis’Board to display the new distribution board entry dialogue.Enter the name of the distribution board using less than twenty characters. (Spaces arepermitted).


Click OK to create the distribution board database file. The new distribution board should nowappear in the Distribution Board list.

Any number of Distribution boards may be added to a project file.

3) Save a circuit within the Distribution board file.

If you have just performed a calculation then you may save the calculation results by clicking onthe Save Circuit button.

You will be asked for the following details:-

Circuit Number e.g. 6Phase e.g. RDescription e.g. Office 1 LightingInstallation method e.g. PVC in conduit

Click OK to save the data.

If you want to save data for a circuit from scratch without performing a calculation (Inspectionand testing) then this can be done by clicking on the Edit circuit button.

Before the main circuit database entry screen appears a message with a reminder to click the addcircuit button before adding a new circuit will be displayed. What this means is that beforefilling in all the data for a new circuit you must first establish the new circuit in the database, ifthis is not done then the new data will not be saved. This needs to be done for each NEW circuitthat you add. Once the circuit has been established you will not need to use the Add Circuitbutton again for that same circuit.

Any number of circuits may be added to a distribution board file.

Click on the ‘load circuit’ button to continue.

To calculate and save a cable

To calculate a cableFirst select the appropriate distribution board from the list in the ‘project manager’. This willthen load the supply characteristics for that distribution board in to the cable calculator, in thecable calculator window. Fill in the circuit number, phase and description boxes and thenproceed with your calculation as normal then click ‘save’ on completion. Confirm details in the‘save circuit’ screen and click ok.


To calculate a sub main cable.From the ‘Project Manager’, select the distribution board that the cable is coming from, then onthe cable calculator screen select ‘sub main’ and then select three phase if relevant. A yellowgrid should now be visible. In the left column of the grid add the load in amperes, in the middlecolumn the distance in metres, then when you click to the right column a drop down list willappear, select the relevant distribution board that the cable is feeding. If your sub main cable islooping to more than one distribution board then complete section two as appropriate. Click okand then go back to the cable calculator screen and continue as normal. Another yellow grid willappear displaying the result of the sub main(s), click ok to continue, and then click on ‘save’.

CASTLINE SYSTEMS Cablecalc Utilities •••• 39

Utilities

The Time Curve Utility.The Cablecalc “Plus” for Windows Time/Current curve utility has been developed to producegraphs for displaying protective device time/current characteristics for a large number ofcommonly used fuses and circuit breakers.

The menusFileSave to File

Enables the displayed graph to be saved as a bitmap image (*.bmp). Select this option if youintend to add the graph to a document created in any other Windows programme. Oncecreated and then exported to a Windows desktop publishing or Word-processing programmethe bitmap images may be sized as required.

Print GraphThis will send a copy of the displayed graph to the local printer. If your printer is a colourprinter then the print will be in colour. Note: Beware of using dark background colours whenusing ink jet printers as this will tend to make the graph lines merge into the backgroundresulting in a messy print out.


ExitExits Time Curve and returns to the main Cablecalc for Windows screen.

Set UpColours

Select the screen colours for: -

Graph background

Graph border

Graph curve lines

Graph log-log lines

Graph text

Graph time indication

Three buttons are displayed at the bottom of this form and are as follows: -

OKThis will save the colours that you have selected

CancelThis will quit the Colour set up option without saving the changes

Set defaultThis will reset the screen colours to the default colour scheme.

Disconnection TimeThis will enable the user to produce a graph displaying an accurate assessment ofdisconnection time or operating time for a protective device.

Disconnection time or operating time is the time taken from the commencement of a currentlarge enough to cause the fuse elements to melt (or in the case of a circuit breaker, themechanical contacts to separate), through to the breaking of the circuit. The protective devicemust be capable of breaking the circuit before any overload current (If) can cause a rise intemperature which may damage the current carrying conductor or any of its associatedequipment.

1) Select Disconnection Time from the menu to reveal the datainput screen.

2) Select the type of protective device from the Select protectivedevice list.

3) Select the Rating of the protective device by clicking on the upand down arrows.

4) Input the Fault current in Amperes, (this will automaticallydisplay the Fault current from the last calculation performed inCablecalc for Windows)

5) Select continue to calculate and view the results on screen.


DiscriminationDiscrimination of a protective device is the requirement to co-ordinate overload and shortcircuit protection by assessing the characteristics of the devices used so that energy let throughby one device does not exceed that of any upstream protective device or devices. The total I²tlet through energy of the smaller device should not exceed or be too close to the prearcingvalue of the next larger device. If it is larger then the larger device could operate before thesmaller device.

To illustrate this situation Cablecalc “Plus” Time / Curve will allow any number of protectivedevices to be displayed at any one time. As a general rule, if the curve of a device touches oroverlaps that of any other device then discrimination is not achieved and the larger devicecould be the first to fail.

1) Select Discrimination, and then select Add ProtectiveDevice from the menu to reveal the data input screen.

2) Select the type of protective device from the Selectprotective device list.

3) Select the Rating of the protective device by clicking on theup and down arrows.

4) Select continue to display the protective devicecharacteristics on screen.

5) Repeat as required.

Fault LinesA conductor fault line is a line plotted against a graph showing the maximum fault a currentcarrying conductor can withstand for a given disconnection time. When a conductor line issuperimposed against a protective device time / curve, where the line crosses the curveindicates the maximum disconnection time for that particular cable and insulationcombination. As a general rule of thumb, if the fault line is to the right of the curve then thesituation is acceptable.

1) Select Fault Lines from the menu to reveal the data inputscreen.

2) Select the type of protective device from the Selectprotective device list.

3) Select the Rating of the protective device by clicking on theup and down arrows.

4) Select the type of Conductor from the available Conductoroptions

5) Select the type of Insulation from the available Insulationoptions

6) Select the Size of cable from the Cable Size list.

If you wish to display disconnection time as well as a conductor fault line, then Input the faultcurrent in Amperes. (This will automatically display the Fault current from the last calculationperformed in Cablecalc for Windows). If this input is left blank then no disconnection timecharacteristics will be displayed.

Select continue to calculate and view the results on screen.


ClearUse this menu option to clear all items from the graph.

The Conduit UtilityCablecalc “Plus” for Windows Conduit size utility may be used to determine capacities ofconduits using the method described in Appendix A “Cables capacities of conduit & trunking”of the guidance notes for the 16th Edition Wiring Regulations (Number 1 - Selection &Erection). The units used for the calculation are terms, as used by the British ElectricalSystems Association (BESA) and are based upon diameter.

The menusFileSave

Saves the current calculation as a *.con file.

OpenLoads and opens an existing file.

NewCreates a new file.

PrintPrints the current file data.

AboutDisplays an overview of Conduit Size


ExitExits Conduit and returns to the main Cablecalc for Windows screen.

HelpGetting Help

Displays a message on how to obtain help

KeysDescribes the short-cut keys

The following inputs may be performed in any order: -

Select the length of the conduit run from length of run list

Select the number of bends in the conduit run from the Number ofbends list.

Select the size of conduit from the Conduit size list.

Input the number of cables for each relevant cable size in the data entry grid, the terms percable and the total terms are automatically displayed in the adjacent grid cells.

Important To accept the quantity into the calculation you must either press the enter key ormove to another grid cell using either the up or the down arrow keys

The totals are displayed beneath the grid for the number of cables (regardless of size and thenumber of terms).

DisplaysThe % used

Is the percentage of the conduit that is used, if this figure exceeds the predetermined criteria aFAIL message will appear.

The % spareIs the percentage of the conduit that is not used, if this figure exceeds the predeterminedcriteria a FAIL message will appear.

Default % settingThe default setting is the percentage relative to the recommended maximum capacitypermitted by the IEE regulations (This is regarded as 100%). The provision to change thisfigure is useful for providing space for future expansion or additions to the installation. i.e. aspecification may require that all conduits have a free capacity of 25% for future expansion, inwhich case the default % would be set by the user to 75%. This will ensure that all conduitsare filled to within the specified limits.

The buttons at the bottom of the conduit screen duplicate the menu options listed previously


The Trunking UtilityCablecalc “Plus” for Windows Trunking size utility may be used to determine capacities oftrunking using the method described in Appendix A “Cables capacities of conduit & trunking”of the guidance notes for the 16th Edition Wiring Regulations (Number 1 - Selection &Erection). The units used for the calculation are terms, as used by the British ElectricalSystems Association (BESA) and are based upon diameter.

The menusFileSave

Saves the current calculation as a *.trk file.




AboutDisplays an overview of Trunking Size

ExitExits Trunking and returns to the main Cablecalc for Windows screen.

HelpTo obtain on line help press the F1 function key.


The following inputs may be performed in any order:-

Select the size of trunking from the Trunking size list.

Input the number of cables for each relevant cable size in the data entry grid.

The total number of cables is automatically displayed regardless of size in the total box.

DisplaysThe % used

Is the percentage of the trunking that is used, if this figure exceeds the predetermined criteria aFAIL message will appear.

The % spareIs the percentage of the trunking that is not used, if this figure exceeds the predeterminedcriteria a FAIL message will appear.

Default % settingThe default setting is the percentage relative to the recommended maximum capacitypermitted by the IEE regulations (This is regarded as 100%). The provision to change thisfigure is useful for providing space for future expansion or additions to the installation. i.e. aspecification may require that all trunking runs have a free capacity of 25% for futureexpansion, in which case the default % would be set by the user to 75%. This will ensure thatall trunking runs are filled to within the specified limits.

The buttons at the bottom of the trunking screen duplicate the menu options listed previously.

The Diversity UtilityAllowances for Diversity are determined using the method described in Appendix J “MaximumDemand and Diversity” of the guidance notes for the 16th Edition Wiring Regulations (Number 1- Selection & Erection).


The menusFileSave

Saves the current calculation as a *.dvy file.




ExitExits Diversity and returns to the main Cablecalc for Windows screen.

AboutDisplays an overview of Diversity.

HelpTo obtain on line help press the F1 function key.

To calculate diversity first select the type of premises from the premises options: -

Individual Household installations

Small shop, stores, offices, business premises

Small hotels, boarding, guest houses etc.

The following inputs may be performed in any order: -

Lighting

Heating


Cooking

Motors

Water heaters (instantaneous)

Water heaters (thermostat)

Floor warming

Storage heaters

Final circuits

Socket outlets

Input the Load in Amperes for the relevant items, the full load current and the diversified currentare automatically displayed in the totals boxes.

CASTLINE SYSTEMS Cablecalc Trouble Shooting •••• 49

Trouble Shooting

VersionTo find the version number of the programme on your computer select ‘About’ from the ‘Help’drop down menu.

Where to look for answersIf your problem is of an electrical nature, such as a calculation that seems to be giving strangevalues or failing unnecessarily, examine the Calculation Related Problems below. Otherwise, ifthe computer just wont print, or you have other problems of this nature, refer to ComputerRelated Problems. If you are having problems in using the programme we recommend that youuse the Cablecalc for Windows Getting Started featured earlier.

Computer Related Problems

The following covers possible problems of a computer nature that may be encountered whenusing Cablecalc for Windows, together with suggested solutions.

1. Some Laser printers may have difficulty printing this on-line manual often resulting in amemory error as well as it printing in three or more sections. If this happens to you, youmay need to change the settings on the printer in Windows. Try decreasing the settingmarked resolution to 150 dpi (see your Windows manual for details on how to do this).

NOTE: The manual may take up to ten minutes to print, including a large pause before the printer starts working. This is quitenormal, and is not a problem with the software or your system. However, you should ensure that you have at least 4 Megabytes offree space on your hard disk to accommodate the temporary print file before starting to print.

2. When selecting fonts for the calculation printout always run a Print Preview beforedeciding on a font to use because some fonts produce unexpected effects (and can beunreadable, if a font such as Symbol or Wingdings is selected!). If in doubt, stick to thestandard two readable fonts that are supplied with Windows, Times New Roman and Arial.

3. If the software prints a demonstration Watermark across all the printouts this normallymeans that the software is either a demonstration version of the programme or that it is thefull version but has been incorrectly installed. If this happens (and you are NOT running ademonstration copy) check at the top of the screen to see if you are running the correct


level. If the level is displayed as ‘Level 0’ then the software has been incorrectly installed.In the event of this happening to you, in the first case try re-installing the software using thecorrect method. If this still does not cure the problem, contact Castline Systems.


Operation problems

Error codes

5 Illegal function call

6 Overflow

7 Out of memory

9 Subscript out of range

11 Division by zero

13 Type mismatch

28 Out of stack space

48 Error in loading DLL

51 Internal error

52 Bad file name or number

53 File not found

54 Bad file mode

55 File already open

57 Device I/O error

58 File already exists

61 Disk full

67 Too many files

68 Device unavailable

70 Permission denied

71 Disk not ready

74 Cannot rename with differentdrive

75 Path / File access error

76 Path not found


Most of the above errors are self evident but care must be taken to input the correct data,omitting data may cause the programme to error.

Error numbers 5 to 51 are mathematical / data errors

Error numbers 52 to 76 are disk / file / path errors

Printer Errors should be trapped by the operating system

CASTLINE SYSTEMS Cablecalc Glossary of Terms •••• 53

Glossary of Terms

NICEIC

NationalInspectionCouncil forElectricalInstallationContracting

P.F.

Power Factor

Pscc

ProspectiveShort CircuitCurrent

Ze

Phase earthloopimpedancefrom thesource ofenergy to theend of a finalcircuit



Index

A

Ambient Temperature .............................. 13

B

Bitmap Image........................................... 39Buttons..................................................... 32

C

Cable Calculator ...............10, 12, 14, 32, 33Cable Size ................................................ 27Cables ...................................................... 20Calculate and Save a Cable ................ 17, 36Calculation Errors .............................. 12, 27Calculation method .................................. 24Calculation related problems .................... 28Computer Related Problems..................... 49Correction Factor ..................................... 24Create Distribution board ......................... 14Create Project file..................................... 35

D

Discrimination ......................................... 41Distribution Board ....................7, 33, 35, 36Diversity .................................................. 19Diversity Utility ....................................... 45

E

Elite ........................................................... 8Error codes............................................... 51

F

Fail..........................................12, 28, 43, 45Fault Lines ............................................... 41Formulae and Conversion......................... 15

G

Grouping (Cg).......................................... 23

H

Help ......................................................... 10Hint Button .............................................. 12

I

Impedance................................................ 28

Index Tabs ............................................... 10Installation ................................................. 9

L

Laser Printers ........................................... 49Lighting Circuit.................................... 8, 18Load........................................17, 18, 28, 47

M

Menus ...................................................... 33Motor....................................................... 19Multiplier ................................................. 22

O

Operation problems.................................. 51Overload / short circuit protection ............ 21

P

Plus............................................................ 7Power Factor...................................... 14, 53Print Graph .............................................. 39Print Preview ............................... 12, 27, 49Printing Reports ....................................... 11Professional................................................ 8Project Default Values.............................. 13Project Manager .... 11, 12, 13, 14, 31, 34, 37Projects A Beginners Guide ..................... 34

R

Radial Circuit ........................................... 17Resolution............................................ 9, 49Ring Circuit ............................................. 18

S

Sample File .............................................. 12Save a circuit within the Distribution board

file. ....................................................... 36Saving Your Work ................................... 11screen resolution ........................................ 9Select CPC............................................... 25Select Protective Device........................... 21Set Defaults........................................ 10, 17Setting up a Project File ........................... 13Setting Your Printer ................................. 11Short Circuit Current.......................... 14, 53Star Delta circuit ...................................... 18Starting a Calculation............................... 10Starting Cablecalc .................................... 10Sub main.................................................. 18Supplied from .......................................... 14Supply Details.......................................... 14


Supply Impedance.................................... 13Supply Voltage ........................................ 13

T

Tab 1 - Supply ......................................... 17Tab 2 - Cables.......................................... 20Tab 3 - Protection .................................... 21Tab 4 – Derating ...................................... 23Tab 5 - CPC Details ................................. 25Tab 6 - Calculate...................................... 27Temperature (Ca)..................................... 23The Cable Calculator ............................... 17The Conduit Utility .................................. 42The Project Manager................................ 31The Time Curve Utility. ........................... 39Thermal insulation (Ci) ............................ 23To Calculate a Cable................................ 36To Calculate a Sub Main Cable.......... 18, 37Trouble Shooting ..................................... 49Trunking Utility ....................................... 44Type of Circuit................................... 17, 21

U

User Ddefaults ......................................... 17Utilities.................................................... 39

V

Volt Drop .....................................13, 27, 29

Documents

cablecalc